Real time flow rate meter
A system and method for calibrating discharge coefficients using either an orifice plate flow rate meter or a venturi flow rate meter in a well operation is provided. Using differential pressures obtained from the flow rate meter along with real time calibration of the discharge coefficient with density and rheology data, the flow rate meter can be used in a much more analytical manner. In this way, real time detection of influx or cuttings can be determined in real time, along with estimated concentrations.
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This disclosure relates, in general, to a real time flow rate meter and, more particularly, to a real time calibrated flow rate meter equipment using an orifice plate or venturi meter that enables calibration of cuttings transport models used in drilling programs, among other features.
BACKGROUNDWithout limiting the scope of the present disclosure, its background will be described with reference to an environment used for producing fluid from a hydrocarbon bearing subterranean formation, as an example. Natural resources, such as oil or gas, residing in a subterranean formation can be recovered by drilling a wellbore that penetrates the formation. A variety of fluids can be used in both drilling and completing the wellbore and in resource recovery. Example fluids include drilling fluids, also called mud that may be pumped into the wellbore during drilling and similar operations; spacer, which helps flush residual drilling fluid from the well bore; and fracturing fluids, which may be used to enhanced oil or natural gas recovery.
During the completion of a well that traverses a hydrocarbon bearing subterranean formation, or during downhole cleaning operations, changes in content of fluid flow can have impacts on efficiencies or safety of the operations. Event detection of fluid density or viscosity changes are useful to alert operators for monitoring or for altering operational parameters, such as, e.g., drilling speed, for improved safety or increased production.
Accordingly, a need has arisen for improved real time detection of wellbore influx drilling fluid density or viscosity changes during well operations such as for forecasting mass flow rate of the influx.
For a more complete understanding of the features and advantage of the present disclosure, reference is now made to the detailed description along with the accompanying figures in which corresponding numerals in the different figures refer to corresponding parts and in which:
In the following detailed description of the illustrative embodiments, reference is made to the accompanying drawings that form a part hereof. These embodiments are described in sufficient detail to enable those skilled in the art to practice the disclosed subject matter, and it is understood that other embodiments may be utilized and that logical structural, mechanical, electrical, and chemical changes may be made without departing from the spirit or scope of the disclosure. To avoid detail not necessary to enable those skilled in the art to practice the embodiments described herein, the description may omit certain information known to those skilled in the art. The following detailed description is, therefore, not to be taken in a limiting sense, and the scope of the illustrative embodiments is defined only by the appended claims.
As used herein, the singular forms “a”, “an,” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms “comprise” and/or “comprising,” when used in this specification and/or the claims, specify the presence of stated features, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, steps, operations, elements, components, and/or groups thereof. In addition, the steps and components described in the above embodiments and figures are merely illustrative and do not imply that any particular step or component is a requirement of a claimed embodiment.
Unless otherwise specified, any use of any form of the terms “connect,” “engage,” “couple,” “attach,” or any other term describing an interaction between elements is not meant to limit the interaction to direct interaction between the elements and may also include indirect interaction between the elements described. In the following discussion and in the claims, the terms “including” and “comprising” are used in an open-ended fashion, and thus should be interpreted to mean “including, but not limited to.” “Downhole” refers to a direction towards the end or bottom of a well. “Uphole” refers to a direction generally towards the top of a well or towards the surface. “Downstream” generally refers to a direction generally towards a wellhead, or towards the end or bottom of a well. The terms “about” or “substantially” refers to within +/− 10%, unless context indicates otherwise.
A pump 120 (e.g., a mud pump) circulates drilling fluid 122 through a feed pipe 124 and to kelly 110, which conveys drilling fluid downstream through the interior of drill string 108 towards and through one or more orifices of the drill bit 114. The return drilling fluid 122 is then circulated uphole back to the surface 101 via an annulus 126 defined between the drill string 108 and the walls of the wellbore 116. At the surface 101, the recirculated or spent drilling fluid, i.e., return drilling fluid 122, possibly including hydrocarbons, exits annulus 126 and may be conveyed via interconnecting flow line 130 through a flow rate meter assembly 128, and onward to fluid processing units (not shown) and/or retention pit 132. A mixing hopper 134 may be present coupled to or in communication with the retention pit 132. The mixing hopper 134, which may be any of a wide variety of different mixing equipment, may be used to add materials to the drilling fluid 122.
The flow rate meter assembly 128 may comprise an orifice plate or a venturi configured within a return flow line, such as flow line 130, or another portion of the return fluid flow path. The orifice plate 145, or a venturi 129 (
Generally, traditional orifice types of devices are usually suited for fluids that have a fairly constant density and consistent viscosity. Basic operating physics is derived from the Bernoulli and continuity equations with the discharge coefficient, Cd, being selected and/or calibrated experimentally.
q=Cd A2[2(P1−P2)/Den(1−(A2/A1)2)]1/2
where, A2=orifice area (m2), A1=pipe area (m2), d=orifice diameter (m), D=pipe inside diameter (m), P1−P2=differential pressure (N/m2), q=flow rate (m3/s), Den=fluid mass density (kg/m3). A1=π (D2/4). A2=π (d2/4). π=3.14159.
Since drilling fluids may have various densities and viscosities, measurements of flow rates using traditional orifice plate techniques can have large errors. Without an ability to calibrate the discharge coefficient with fluid changes, it typically is not suitable for measuring flow rates in well systems. However, with real time calibration of the discharge coefficient with density and rheology data, an orifice plate (or venturi) can be used in a much more analytical manner. Some of the techniques include:
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- Viscosity and density data from a BaraLogix® (trademark of Halliburton Corporation) system, or similar system that can autonomously provide fluid density and rheology to calibrate the discharge coefficient. In this manner, overall performance is better to detect changes in fluid properties, such as changes in concentration or density. This technique performs well as a mass flux device or flow rate device for drilling fluids. Moreover, corrections for temperature of the fluid flowing through the flow rate meter can be applied, along with updated discharge coefficients based on density and viscosity measurements.
- Detection of slugs and cuttings that cause density variations, or concentration changes, due to cutting concentration in the flow stream is now possible.
- Detection of wellbore fluid influx is now possible and the ability to forecast the mass flow rate of the influx is possible with calibration.
- With a calibrated flow meter, detection of treatment pills or spacers clearing the wellbore to predict the density of the mixed interface fluids in real time is possible. Integrating the measured density with the predicted density provides a real time analysis of the wellbore cleaning efficiency. In some cases, this may lead to an extended clean-up procedure being initiated to ensure proper wellbore cleanup has been achieved.
A real-time operations database 180, which may be a part of the BaraLogix system 115, or a remote database such as an InSite® database (InSite® is a registered trademark of Halliburton Corporation), may monitor rotations per minute (RPM) of the drill bit, rate of penetration (ROP), and weight on bit (WOB), given the fluid density and rheology 183 from the BaraLogix® DRU 115, and flow rate information from flow rate meter assembly 190. The flow rate meter assembly 190 may provide output data to the BaraLogix® DRU 115 and/or the real-time operations database 180, if the real-time operations database 180 is implemented separately from the BaraLogix® DRU 115. These are related to the drilling mechanics and ideally are monitored/controlled to obtain an optimal performance of a drilling operation.
An event notification system 185, which may be a part of the BaraLogix® DRU 115, may monitor for an event given the fluid density and rheology 183, q (flow rate at the flow meter), t (temperature, typically taken at the flow rate assembly 190), and qs (flow rate proximate or within a fluid pump, e.g., at pump 120 provided to BaraLogix® DRU 115). Rheology and/or density infers discharge coefficient Cd. Therefore, computing flow rate for both q and qs employing equation q=Cd A2 [2 (P1−P2)/Den (1−(A2/A1)2)]1/2 permits a determination as follows:
-
- a) qs<q infers cuttings are present in the fluid flow, typically arising from the cutting due to the drill bit operations.
- b) qs>q infers influx of hydrocarbons (and/or water).
Wellbore treatment fluids are subject to thermal expansion and hence a density change when they are heated. It is common for the flow line temperatures to exceed 120 F and in some extreme cases, the temperature might be as high as 200 F. This range of temperatures can cause a change in fluid density. For calibrating the Cd, the density of the fluid must be known at a reference temperature and then the density can be projected at any temperature for calibration purposes. The BaraLogix® unit provides this capability. The BaraLogix® unit measures density at the same temperature and is slightly pressurized to minimize gas bubbles. Thus, with a known starting temperature and the composition of the fluid, the fluid density at any temperature in the flow line can be predicted, thereby providing a calibrated system.
For a given orifice geometry, the discharge coefficient is a function of density (ρ), dynamic viscosity (μ) and flow velocity (u), Cd=f (ρ, μ, u). A simple correlation can be expressed as Cd=Cp*Cc*Cu, where Cp is the velocity profile coefficient, Cc is the vena contracta coefficient (area ratio of the orifice) and Cu the viscosity coefficient. For low Reynolds number, Cp is invariant, Cc is unity and the instant above equation reduces to be proportional to √ Re. This indicates that the viscous effect is dominant at the region. For turbulent flow at high Reynolds number, the typical orifice can be characterized by the Newtonian (e.g., water, base oil) in the turbulent region and the “clean” drilling fluid in the laminar region. This can be created offline to generate a database for the correlation between the discharge coefficient and the fluid properties (density and rheology). A model can be created to quantitatively obtain the concentration of cutting contamination as well as gas/water influx. For expediency, a table look-up can be employed.
Based on the determination at step 208, action can be taken accordingly, For example, if cutting is deemed present at a specific concentration or higher, e.g., at step 210, action may be taken to slow down the drilling operation, such as reducing drill bit rotation rate. If influx is deemed present, e.g., step 212, at a specific concentration or higher, then predetermined safety measures may be taken, such as, e.g., to avoid a blowout.
In aspects of the disclosure, the following descriptions may apply.
Clause 1: A method for calibrating a discharge coefficient for well operations, comprising:
-
- receiving a differential pressure indication of a rate of fluid flow in a flow line of a well operation;
- determining viscosity and density data of the fluid flow;
- determining a discharge coefficient using the differential pressure indication and the viscosity and density data;
- comparing the determined discharge coefficient to a prior determined discharge coefficient of the fluid flow; and
- ascertaining the presence of one of: cuttings in the fluid flow and influx in the fluid flow based on the comparing step.
Clause 2: The method of clause 1, wherein the differential pressure indication is received from an orifice plate flow rate sensing device.
Clause 3: The method of clause 1, wherein the differential pressure indication is received from a venturi flow rate sensing device.
Clause 4: The method of any one of clauses 1-3, wherein the step of determining a discharge coefficient using the differential pressure indication and the viscosity and density data includes using real time wellbore fluid rheology and density data.
Clause 5: The method of any one of clauses 1-4, wherein the discharge coefficient is calibrated with the viscosity and density data providing a calibrated flow rate sensing device.
Clause 6: The method of any one of clauses 1, 2, 4 or 5 wherein the step of receiving the differential pressure indication of a rate of fluid flow in the flow line is provided by a orifice plate flow meter.
Clause 7: The method of any one of clauses 1-6, further comprising comparing a flow rate at a flow meter measuring return fluid flow from a wellbore to a flow rate at a flow meter at a mud pump pumping fluid into a wellbore to detect a change in downhole conditions including at least one of: an influx of a fluid and a change in concentration of cuttings.
Clause 8: The method of clause 7, wherein the influx of a fluid includes at least one of a hydrocarbon and water.
Clause 9: The method of any one of clauses 1-8, wherein in the step of determining the discharge coefficient includes obtaining the discharge coefficient from a lookup table or from a model.
Clause 10: The method of any one of clauses 1-9, further comprising detecting slugs of cuttings in the fluid flow.
Clause 11: The method of any one of clauses 1-10, further comprising detecting treatment pills or spacers clearing a wellbore and predicting a density of mixed interface fluids in real time.
Clause 12: A method of calibrating a discharge coefficient for well operations, comprising:
calibrating in real time, a discharge coefficient using a pressure indication from an orifice flow meter assembly monitoring return drilling fluid flow from a wellbore, and using viscosity and density data of the return drilling fluid flow; and
detecting one of: cuttings and influx in the return drilling fluid flow.
Clause 13: The method of clause 12, further comprising detecting treatment pills or spacers clearing the wellbore.
Clause 14: The method of clause 12 or 13, further comprising predicting a concentration of the cuttings or predicting a mass flow rate of the influx.
Clause 15: The method of any one of clauses 12-14, further comprising comparing a flow rate of the return drilling fluid flow at the orifice flow meter with a flow rate at a pump pumping drilling fluid into the wellbore to detect a change in wellbore conditions.
Clause 16: A system for calibrating a discharge coefficient for well operations, comprising:
a flow rate meter that provides a pressure indication of return drilling fluid flow;
a device to determine a discharge coefficient using the pressure indication and viscosity and density data determined by density and rheology of the return drilling fluid flow; and
a device to identify cuttings or influx in the return drilling fluid flow based on the determined discharge coefficient and a prior determined discharge coefficient.
Clause 17: The system of clause 16, wherein the flow rate meter comprises a calibrated orifice plate flow rate meter.
Clause 18: The system of clause 16, wherein the flow rate meter comprises a venturi flow rate meter.
Clause 19: The system of any one of clauses 16-18, wherein the device to identify cuttings or influx further detects treatment pills or spacers clearing the wellbore.
Clause 20: The system of any one of clauses 16-19, wherein the device to identify cuttings or influx further detects slugs.
The embodiments set forth herein are merely illustrative and do not limit the scope of the disclosure. It will be appreciated that many other modifications and improvements to the disclosure herein may be made without departing from the scope of the disclosure.
Claims
1. A method for calibrating a discharge coefficient for well operations, comprising:
- receiving a differential pressure indication of a rate of fluid flow in a flow line of a well operation;
- determining viscosity and density data of the fluid flow;
- determining a discharge coefficient using the differential pressure indication and the viscosity and density data;
- comparing the determined discharge coefficient to a prior determined discharge coefficient of the fluid flow; and
- ascertaining the presence of one of: cuttings in the fluid flow and influx in the fluid flow based on the comparing step.
2. The method of claim 1, wherein the differential pressure indication is received from an orifice plate flow rate sensing device.
3. The method of claim 1, wherein the differential pressure indication is received from a venturi flow rate sensing device.
4. The method of claim 1, wherein the step of determining a discharge coefficient using the differential pressure indication and the viscosity and density data includes using real time wellbore fluid rheology and density data.
5. The method of claim 1, wherein the discharge coefficient is calibrated with the viscosity and density data providing a calibrated flow rate sensing device.
6. The method of claim 1, wherein the step of receiving the differential pressure indication of a rate of fluid flow in the flow line is provided by a orifice plate flow meter.
7. The method of claim 1, further comprising comparing a flow rate at a flow meter measuring return fluid flow from a wellbore to a flow rate at a flow meter at a mud pump pumping fluid into a wellbore to detect a change in downhole conditions including at least one of: an influx of a fluid and a change in concentration of cuttings.
8. The method of claim 7, wherein the influx of a fluid includes at least one of: a hydrocarbon and water.
9. The method of claim 1, wherein in the step of determining the discharge coefficient includes obtaining the discharge coefficient from a lookup table or from a model.
10. The method of claim 1, wherein in the step of ascertaining, the ascertaining detects slugs in the fluid flow.
11. The method of claim 1, further comprising detecting treatment pills or spacers clearing a wellbore and predicting a density of mixed interface fluids in real time.
12. A method of calibrating a discharge coefficient for well operations, comprising:
- calibrating in real time, a discharge coefficient using a pressure indication from an orifice flow meter assembly monitoring return drilling fluid flow from a wellbore, and using viscosity and density data of the return drilling fluid flow;
- comparing the determined discharge coefficient to a prior determined discharge coefficient of the return drilling fluid flow; and
- detecting one of: cuttings and influx in the return drilling fluid flow based on the comparing step.
13. The method of claim 12, further comprising detecting treatment pills or spacers clearing the wellbore.
14. The method of claim 13, further comprising predicting a concentration of the cuttings or predicting a mass flow rate of the influx.
15. The method of claim 12, further comprising comparing a flow rate of the return drilling fluid flow at the orifice flow meter with a flow rate at a pump pumping drilling fluid into the wellbore to detect a change in wellbore conditions.
16. A system for calibrating a discharge coefficient for well operations, comprising:
- a flow rate meter that provides a pressure indication of return drilling fluid flow;
- a device to determine a discharge coefficient using the pressure indication and viscosity and density data determined by density and rheology of the return drilling fluid flow; and
- a device to identify cuttings or influx in the return drilling fluid flow based on the determined discharge coefficient and a prior determined discharge coefficient.
17. The system of claim 16, wherein the flow rate meter comprises a calibrated orifice plate flow rate meter.
18. The system of claim 16, wherein the flow rate meter comprises a venturi flow rate meter.
19. The system of claim 16, wherein the device to identify cuttings or influx further detects treatment pills or spacers clearing the wellbore.
20. The system of claim 16, wherein the device to identify cuttings or influx further detects slugs.
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Type: Grant
Filed: Oct 28, 2019
Date of Patent: Oct 12, 2021
Patent Publication Number: 20210123789
Assignee: Halliburton Energy Services, Inc. (Houston, TX)
Inventors: Dale E. Jamison (Humble, TX), Xiangnan Ye (Cypress, TX)
Primary Examiner: Herbert K Roberts
Assistant Examiner: John M Royston
Application Number: 16/666,203
International Classification: G01F 25/00 (20060101); E21B 21/08 (20060101); G01N 33/28 (20060101); G01F 1/36 (20060101);